Reusable inflatable packing system with tab valve

ABSTRACT

A reusable, inflatable packing system comprised of a multi-chambered shipping pad formed of first and second outer film layers and a third, central layer located between at least a portion of the outer layers, and having two or four discrete inflatable zones, wherein each zone is further comprised of a plurality of inflatable chambers, preferably conical in shape. The multi-chamber design facilitates absorption of impact upon the pad by permitting redistribution of an inflation gas, e.g., air, from an area of impact to a non-impacted area removed a distance therefrom within the same zone. The flow of inflation gas into and/or out of the pad zones is controlled by at least one tab valve assembly, each of which is comprised of a main and a working tab valve frame, which main frame is mounted within an outer film layer while the working frame is mounted in the central film layer. Sealing the central film along its opposed longitudinal ends to respectively, the first and second outer films forms air pockets adapted for directing air entering through the valve frames into respective zones of the pad. The tab valve assembly contains no moving parts and is closed or opened by snapping together or peeling apart the two valve frames comprising the assembly. When snapped together, the security of the snap seal is ensured by the use of a three point locking system molded into the valve frames.

FIELD OF THE INVENTION

[0001] The invention is directed to an impact-resistant packing system for protecting articles during shipping from shock and damage and, more particularly, to a reusable, inflatable multi-zone shipping pad wherein control of the inflation gas within the pad zones is respectively provided by one or more tab valve assemblies adapted for permitting independent inflation/deflation of each said zone.

BACKGROUND OF THE INVENTION

[0002] When articles are packaged in a container for shipping, void spaces are typically created between the article and the inner surface of the container. Packaged articles come in a variety of shapes, thus producing a plurality of irregularly shaped voids. A packing material is thus commonly inserted within these voids to cushion and protect the packaged article during shipping.

[0003] It is known, therefore, to at least partially surround shipped articles with packing materials having a variety of shapes and sizes such as Styrofoam® “chips,” injected Styrofoam® moldings, “bubble” mats and other energy absorptive materials. “Bubble” mats are intended to wrap close to the shipped item, providing an enclosure that protects the item, but the spaces between the “bubble” mat protected item and the interior surfaces of the container are largely filled with a volume of a loose fill type material such as Styrofoam® “chips,” or other particulate packing materials that provide a loose fill. The packaged article may settle during transport, reducing the cushioning effect. Moreover all of the above-described packing materials are themselves voluminous to both ship and store. In addition, they could create waste disposed problems with attendant problems of environmental degradation.

[0004] In an effort to overcome the problems noted above, various forms of inflated cushions have been utilized. Such cushions are well known and have been commonly used for some time in the shipment of goods. Several useful examples of inflatable cushions are illustrated in, for example, U.S. Pats. No. 5,427,830; 5,447,235 and 5,487,470 to David A. Pharo. The inflatable packaging systems described therein, and throughout the prior art have been faced with a number of design challenges, however. For example, some of the inflatable cushions include only a single inflatable zone, such that a failure at any location in the packaging material will lead to a total deflation of the system, thus resulting in a total loss of function. Other examples include cushions with a plurality of interconnected inflatable zones, i.e., providing, a “quilted” appearance to the cushion. This arrangement still remains prone, however, to the deflation problem described above. Still other embodiments comprise a plurality of discrete, i.e., separate, chambers, which do not, as is desirable, permit redistribution of air within the pad, i.e., from one chamber to another, upon impact to the outer surface of one or more such chambers.

[0005] Additionally, many such prior art inflatable packing systems are further subject to other problems caused due to the use of valve systems that may channel air under impact pressure directly toward the valve cap, thus forcing open the valve, or self-sealing valves that are most effective when cushions maintain a consistent pressure once inflated. This consistent pressure provides a back pressure helping to make the valve self-sealing. Thus, the dimensions of these inflatable cushions may find it difficult to adjust to different sized voids within a packing container. Still further, due to the very nature of the self-sealing valves, such inflatable devices are typically not readily reusable since it is difficult, if not impossible, to empty the air out of an inflated cushion or pad without reducing the useful life of each cushion, i.e., puncturing the cushion or disrupting the self-sealing properties.

[0006] It is thus readily apparent that there exists a long-felt need, which is satisfied by the present invention as described herein, for a reliable, efficient, adjustably inflatable protective packaging system, with a reusable multi-locking valve, for protecting fragile and/or valuable items during shipping. The present invention meets these requirements with a simple design that is readily and conveniently manufactured from inexpensive starting materials. It may be used, and reused, for an unlimited variety of shapes and sizes of product being packaged. The system includes a protective inflatable pad that is self-adapting to the size and shape of the item being packaged, which will not settle during shipment, and that will secure itself around the object to be shipped while substantially filling all of the void spaces between the object and the outer container. The system of the invention is thus relatively simple to ship and store and it is cost competitive with presently existing systems.

SUMMARY OF THE INVENTION

[0007] It is therefore an object of the invention to provide an inflatable, reusable packing system comprised of a shipping pad formed with at least two separately inflatable and deflatable zones, and further wherein each said zone is comprised of a plurality of interconnected air chambers adapted to facilitate absorption of impact to the pad and to redistribute air from chambers compressed by the impact to alternate air chambers located within each corresponding zone.

[0008] It is another object of the invention to provide the chambers with a conical shape or configuration such that, by balancing the height ratio of the conical chambers it is possible to provide security in the event one of the air chambers is punctured in that adjacent unaffected (i.e., unpunctured) zones will assist in maintaining the width of the pad upon such an event due to the balancing effect provided by the alternating high (i.e., raised) and (relatively) low cone portions.

[0009] It is a further object of the invention to balance restricted entry cones and open entry cones having, respectively, relatively narrow and relatively wide air entry passages, e.g., by alternating these cone types within a particular zone or even throughout the entire pad, to provide additional security against accidental deflation.

[0010] It is another object of the invention to provide an inflatable, reusable shipping pad formed with a cut-out handle portion that separates the various inflatable zones while creating an alternate relief area for air compressed by an impact to the main fill area.

[0011] It is still another object of the invention to provide an inflatable, reusable shipping pad wherein the flow of air into the pad is controlled by at least one “floating” tab valve assembly which, due to its relatively planar construction, allows the valve assembly to withstand a significantly greater air pressure caused due to impact, i.e., causing compression, upon one of the inflated zones of the pad, without forcing the valve open.

[0012] It is an additional object of the invention to provide an inflatable, reusable packing system utilizing a valve assembly, as described above, having a plurality of distinct locking mechanisms configured and adapted to improve the valve integrity.

[0013] These and other objects of the invention are achieved through the use of an inflatable, reusable packing system as described and illustrated herein.

[0014] In a first embodiment the invention is directed to a two zone shipping pad comprising a single tab valve assembly. In a further embodiment, the packing system of the invention comprises a four zone shipping pad utilizing two separate tab valve assemblies wherein each said assembly controls the flow of air into and out of two of said zones. The four zone pad offers additional protection from accidental deflation throughout the shipping process.

[0015] The system of the invention was designed with multiple zones, each formed with multiple air chambers, in a single shipping pad to allow each pad the ability to absorb impact by distributing air to chambers not compressed by the impact. That is, the pad comprises at least two inflation zones, and each said zone may be further broken down into a plurality of inflatable chambers. The shipping pads of the invention can be manufactured in a variety of shapes and sizes, and from a variety of materials as well. FIGS. 14 and 21, illustrating, respectively, a two zone and a four zone pad, display an exemplary geometric design for the pad chambers wherein said chambers are conically shaped. The invention is not limited, however, to the particular arrangement portrayed in the subject drawing figures. That is, whereas a conical configuration is preferred, the chambers of the system of the invention are not limited to a conical shape and may, instead, be configured in a variety of alternate shapes. In the illustrated embodiment, the pad thickness can be increased by making the conical chambers larger. Pads can also be made longer and shorter by adding or subtracting cones from a design layout. This flexibility of design thus provides a custom system useful for a variety of applications, while still offering the same degree of zone security.

[0016] The ability to be inflated or deflated (see, e.g., FIG. 17, FIG. 11) as the task requires, provides a reusable system for all users in a shipping cycle. The shipping pad of the invention can be stored deflated when not in use, thus reducing storage space requirements. The shipping pads may additionally, if desired, be folded (see FIG. 27) prior to being placed in the shipping carton, and then inflated to provide a profile wider than that of a single pad without the necessity of adding additional pads.

[0017] The packing system of the invention makes use of a simple yet novel tab valve assembly that has no mechanical interior parts. Each said valve assembly comprises two tab valve frames, i.e., a main frame and a work frame, located one above the other and an air pocket for each zone created by a dividing film (No. (31) in FIG. 12 and No. (55) in FIG. 19) in which the work frame is installed. The valve frames are e.g., heat welded (they may also be attached to the film via an alternate method such as electrical or chemical bonding) to the appropriate film level as shown, e.g., in FIG. 15 and FIG. 22, such that the main frame (see (21) in FIG. 15) is positioned above the working frame (see (20) in FIG. 15). The working frame is, however, rotated 180° to the main frame in the same plane as the main frame, thus allowing a single frame design to provide two profiles, as shown in FIGS. 1 and 2. This arrangement allows the frame bodies to snap together as shown, e.g., in FIGS. 3 and 10, to form the tab valve assembly.

[0018] The system of the invention, comprising a shipping pad with at least one tab valve assembly, is inflated and deflated through the use of the tab-valve assembly and requires no special equipment to operate. The pads can be filled by mouth or with compressed air, allowing the end user to store, reuse and recycle this packing fill. Security against unintended deflation is thus provided through zone design and the snap locking of the valve frames together as further described herein. The above-described valve system allows air into each zone through a controlling tab valve frame (see (20), (21) in FIG. 15), and can secure the air in the shipping pad by snapping the two valve frames together as shown in FIG. 16. Pressing down on the working frame tab ((2) in FIG. 2), and lifting up on the main frame tab ((2) in FIG. 1), will snap open the valve assembly and allow the pad to be deflated.

[0019] The four-zone embodiment of the shipping pad system of the invention uses two such tab valve assemblies, wherein each said assembly controls the flow into and out of two pad zones (see, e.g., FIGS. 22 and 23).

[0020] The above-described tab valve can be used in a variety of other applications where air containment for simple inflation is required, e.g., for beach and/or pool toys.

[0021] The packing system of the invention may, moreover, be printed with a company logo inside and out, thus advertising a company's policy to conserve energy and recycle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The foregoing objects and other advantages of the present invention will be more fully understood from the following detailed description and reference to the appended drawings, wherein:

[0023]FIG. 1 is a top plan view of a first tab valve frame (referred to herein as the “main” valve frame) which, when snapped together with a second tab valve frame (referred to herein as the “working” or “work” frame and illustrated in FIG. 2) located below the main frame, and which is identical to the main frame but rotated 180° in the same plane as the main frame, forms a tab valve assembly;

[0024]FIG. 2 is a top plan view of the tab valve working frame, illustrating its orientation of this frame with regard to the first (main) frame shown in FIG. 1;

[0025]FIG. 3 is a top plan view of a tab valve assembly formed by snapping together the main and working valve frames illustrated in FIGS. 1 and 2, respectively;

[0026]FIG. 4 is a perspective view of the tab valve assembly shown in FIG. 3;

[0027]FIG. 5 is a perspective view of the tab valve main frame shown in FIG. 1;

[0028]FIG. 6 is a perspective view of the tab valve working frame shown in FIG. 2;

[0029]FIG. 7 is a bottom plan view of a tab valve main frame;

[0030]FIG. 8 is a bottom perspective view of a tab valve frame;

[0031]FIG. 9 is a sectional view through the first and second (i.e., the “main” and “working”) valve frames, illustrating the relative position of these frames when the tab valve assembly is in the open position;

[0032]FIG. 10 is a sectional view through the first and second valve frames shown in FIG. 9 illustrating the relative position of these frames when the tab valve assembly is in the closed position;

[0033]FIG. 11 is a perspective view of a two-zone shipping pad formed in accordance with the invention;

[0034]FIG. 12 is a perspective view of the film layer arrangement used in forming the two zone shipping pad of the invention;

[0035]FIG. 13 is a view similar to FIG. 12 but additionally illustrating the positioning of the main and working valve frames in their respective film layers;

[0036]FIG. 14 is a top plan view of a two-zone shipping pad formed in accordance with the invention;

[0037]FIG. 15 is a sectional view through a tab valve assembly as mounted within the corresponding film layers of a two-zone shipping pad, showing the tab valve assembly in the open position;

[0038]FIG. 16 is a view similar to that in FIG. 15, but illustrating the tab valve assembly in the closed position;

[0039]FIG. 17 is a perspective view of a two-zone shipping pad produced according to the invention, in an inflated condition;

[0040]FIG. 18 is a perspective view of a four-zone shipping pad formed using two tab valve assemblies in accordance with the invention;

[0041]FIG. 19 is a perspective view of the film layer arrangement used in forming a four-zone shipping pad according to the invention;

[0042]FIG. 20 is a view similar to FIG. 19 but additionally illustrating the positioning of two “sets” or pairs of valve frames, used in forming two separate tab valve assemblies adapted for creating four separate inflatable zones, in their respective film layers;

[0043]FIG. 21 is a plan view of a four-zone shipping pad produced in accordance with the invention;

[0044]FIG. 22 is a sectional view through two tab valve assemblies mounted within the corresponding film layers of a four-zone shipping pad showing both assemblies in the open position;

[0045]FIG. 23 is a view similar to that in FIG. 22 illustrating the two tab valve assemblies in the closed position;

[0046]FIG. 24 is a perspective view of a four-zone shipping pad produced in accordance with the invention, in an inflated condition;

[0047]FIG. 25 is a perspective view illustrating an outer shipping container (partially broken away) containing a package therein cushioned by shipping pads produced in accordance with the invention, located at the corners and along the sides of the inner container and extending upwardly and downwardly a sufficient distance to cover at least a portion of the top and the bottom of the inner package;

[0048]FIG. 26 is a view similar to that of FIG. 25 but showing a smaller inner container protected by shipping pads located only in the corners of the outer container; and

[0049]FIG. 27 illustrates a two zone shipping pad folded to fill a void thicker than a single pad.

DETAILED DESCRIPTION OF THE INVENTION

[0050] The invention is therefore directed to an inflatable and reusable multi-zone shipping pad wherein inflation and deflation of each said zone is independently controlled by a novel tab valve assembly comprised of a first, “main” valve frame and a second, “working” valve frame, and further wherein each said zone is comprised of a plurality of, preferably cone-shaped, chambers configured and adapted to help absorb an impact thereupon and, upon such impact, to redistribute air within the pad from a compressed zone or chamber to a non-compressed area, for improving the performance and reliability of the pad.

[0051] Turning now to a description of the components illustrated in the drawing figures, which is thereafter followed by a discussion of how these various components work together in the invention, FIG. 1 illustrates tab valve main frame (1), comprised of a tab portion (2), frame portion (3), valve seat snap lock (4), valve seat opening (5), air portal (6) and valve seat locking ridge (7).

[0052]FIG. 2 illustrates tab valve working frame (8) including, as in main frame (1) discussed above, tab portion (2), frame portion (3), valve seat snap lock (4), valve seat opening (5), air portal (6) and valve seat locking ridge (7).

[0053]FIG. 3 illustrates a tab valve assembly formed by snapping together the tab valve main frame (1) and the working valve frame (8) shown in FIGS. 1 and 2. The assembly is shown in the snapped closed position. Illustrated is main frame portion (3), valve seat snap lock (4), valve seat opening (5), air portal (6), and valve seat locking ridge (7).

[0054]FIG. 4 provides a perspective view of the main and working tab valve frames snapped together to form the tab valve assembly. The main, i.e., top, valve frame (1) is in the upright position and is snapped (and locked, in a manner described below) into the second (working) valve frame (8) which is rotated 180° in the horizontal plane from the position of the main frame. Shown is tab portion (2) of the main valve frame, tab valve frame portion (3), valve seat snap lock (4), valve seat opening (5), air portal (6), and valve seat locking ridge (7).

[0055]FIG. 5 shows, in perspective, a tab valve main frame (1), with tab portion (2) tab valve frame portion (3), valve seat snap lock (4), valve seat opening (5), air portal (6), and valve seat locking ridge (7).

[0056]FIG. 6 illustrates the tab valve working frame (8) in perspective, showing tab portion (2), tab valve frame portion (3), valve seat snap lock (4), valve seat opening (5), air portal (6), and valve seat locking ridge (7).

[0057]FIG. 7 is a rear plan view of a tab valve main frame (1) illustrating the frame portion (3), air portal (6), valve seat stem snap lock (9) and valve seat exterior body (10).

[0058]FIG. 8 is a rear perspective view of a tab valve main frame (1), illustrating valve frame portion (3), air portal (6), valve seat stem snap lock (9), valve seat exterior body (10), and valve seat body groove (11) which is configured and adapted to permit an interlocking, i.e., “snap” fit with locking ridge (7) on a corresponding valve frame.

[0059]FIG. 9 is a sectional view through the two tab valve frames of a tab valve assembly, showing the valve assembly in the open position. Shown are main valve frame (1) and working valve frame (8). Also illustrated are tab valve frame portion (3), valve seat snap lock (4), valve seat opening (5), air portal (6), and valve seat locking ridge (7). Also shown are valve seat stem snap lock (9) for blocking portal (6) when the tab valve assembly is closed, valve seat exterior body (10), and valve seat body groove (11).

[0060]FIG. 10 shows a sectional view through two tab valve frames, with the valve assembly in the closed position. Shown are main valve frame (1), and working valve frame (8), tab valve frame portion (3), valve seat opening (5), valve seat locking ridge (7), valve seat stem snap lock (9), valve seat exterior body (10), valve seat body groove (11), air portal seal (13), which is snap locked, air portal seat snap lock (14), and valve seat body (15) which is also snap locked.

[0061] The valve frames are thus locked together by a three-point locking system wherein: (a) valve seat stem snap lock (9) locks into air portal (6) on working frame (8); (b) valve seat snap lock (4) on working frame (8) locks into air portal (6) on main frame (1); and (c) there is an interlocking fit between valve seat body groove (11) and valve seat locking ridge (7).

[0062]FIG. 11 is a perspective view of a two zone shipping pad layout, and its associated tab valve assembly, as formed in accordance with the invention. Shipping pad zone one (28) retains air delivered to one-half of the pad area, which air is supplied by manipulating the tab portion of the main valve frame (21) (see FIGS. 15, 16) to permit the air to flow into said first zone. Pad zone two (27) retains air delivered to the other one-half pad area, wherein the air is supplied by manipulating the tab valve on the working frame (20) (see FIGS. 15, 16) to permit the air to flow therein. A zone one air pocket (25) is created by pocket notch (23). A zone two air pocket (22) is created by pocket notch (24). The central handle film (described more fully below) separates the air and directs it to the appropriate zone, depending upon the orientation of the tab valve assembly. Tab valve work frame (20) is installed into the shipping pad handle central film (see 31 in FIG. 12). Tab valve main frame (21) is installed in the shipping pad handle top film (see 30 in FIG. 12). Handle cut out (26) separates the two zones.

[0063]FIG. 12 provides a perspective view of a two-zone pad film layout. Lower pad film (29) determines the lower pad dimension from side to side and top to bottom. Upper pad film (30) determines the upper pad dimension from side to side and top to bottom. The central film (31) in the handle portion of the two zone shipping pad (i.e., referred to as the central handle film) creates two air chambers that separate and supply air to each of the two zones. The material used to form the film layers of both the two-zone and the four-zone shipping pads of the invention is the type of plastic material well known in the art for forming inflatable packing materials. Useful film forming materials include, but are not limited to, vinyl, polyethylene, polypropylene, polyester, metallized nylons or other similar material often referred to as “Mylar,” and numerous other air-impervious plastic film compositions. The invention is not limited, however, to the specific film-forming materials listed above as numerous alternative materials would be readily apparent to one of ordinary skill in this art. The particular “plastic” material chosen is not critical to the invention and may be varied among a variety of these known materials in accordance with the intended application for the packing system of the invention

[0064]FIG. 13 is similar to FIG. 12 but shows the relative position of the two valve frames in their respective films. Central film (31) is located in the handle portion of the two zone shipping pad, i.e., separated from the remainder of the pad by handle cut-out (26). It creates two air chambers that each separate and supply air to a respective one of the two zones. As shown, tab valve work frame (20) is installed into shipping pad handle central film (31). Tab valve main frame (21) is installed in the shipping pad handle top film (30).

[0065] Installation of the valve frames is preferably, but not necessarily, carried out by cutting a hole in the film of a suitable size, inserting the valve frame therein, and then securing the frame to the film with the use of, e.g., a heat seal, an adhesive, a sonic weld, or other electric bonding process, or by a chemical bonding process. If desired, the valve frames may be pre-installed at designated locations upon rolls of the film material used in forming the pad layers, whereupon the respective layers are simply matched, cut to an appropriate length, and sealed along their edges and within their interior as required to produce the discrete zones and the respective chambers. In an alternate procedure the film layers (without the valve frames) are matched and cut to an appropriate length, i.e., from a supply roll of such material. Thereafter, the film layers are subjected, at one or more work stations, to a series of processing steps whereupon (not necessarily in the order described): (1) holes are cut in the films wherein the valve frames are installed and sealed to the surrounding film, (2) a handle cut-out is formed, (3) the outer films are sealed along at least their peripheral edges, i.e., by the methods described above, and (4) the central film is sealed at its respective longitudinal edges to, respectively, the top and bottom outer films, to form the respective air chambers.

[0066]FIG. 14 is a top plan view of a two zone shipping pad layout including its tab valve assembly. Shipping pad zone one (28) retains air delivered to one-half the pad area by manipulating the tab portion on main valve frame (21). Zone two (27) of the shipping pad retains air delivered to the other one-half of the pad area by manipulating the tab portion on the work valve frame (20). A zone one air pocket (25) is created by pocket notch (23) wherein the upper film layer (30) is secured to one edge of central film (31), e.g., by heat sealing. Zone two air pocket (22) is created by pocket notch (24) wherein lower film layer (29) is secured to the other (opposed) edge of central film (31). The central film located within the handle area (i.e., the central handle film) separates the air and directs it to the first and second zones, depending on the positioning of the components of the tab valve assembly. Tab valve work frame (20) is installed into shipping pad handle central film (see (31) in FIG. 12). Tab valve main frame (21) is installed in the shipping pad handle top film (see (30) in FIG. 12). Handle cut out (26) separates the zones.

[0067]FIG. 15 is a sectional view through a two zone shipping pad handle portion showing the tab valve assembly in the open position. Shipping pad zone one (see (28) in FIG. 14) retains air delivered to one-half of the pad area, which air is supplied by manipulating the tab portion on valve main frame (21). Zone two (27) of the shipping pad, which comprises the remaining one-half of the pad area, retains air which is supplied by manipulating the tab portion on work frame (20). A zone one air pocket (25) is created by pocket notch (23) formed, as noted above, by sealing together the upper and the central film layers. Zone two air pocket (22) is created by pocket notch (24) formed by sealing the lower and the central film layers. The central handle film directs the air to the first and second zones depending upon the positioning of the components of the tab valve assembly. Tab valve work frame (20) is installed into the shipping pad handle central film (see (31) in FIG. 12). Tab valve main frame (21) is installed in the shipping pad handle top film (see (30) in FIG. 12).

[0068]FIG. 16 is a sectional view through a two zone shipping pad handle assembly including the tab valve assembly, showing the valve assembly in the closed position. As described above, shipping pad zone one (28) retains air delivered to one-half of the pad area, which air is supplied by manipulating the tab portion on main valve frame (21). Shipping pad zone two (27) retains air delivered to the other half of the pad area, wherein the air is supplied by manipulating the tab portion of work valve frame (20). Zone one air pocket (25) is created by pocket notch (23). Zone two air pocket (22) is created by pocket notch (24). The central handle film directs air to the first and second zones, depending upon the arrangement of the components of the tab valve assembly. Tab valve work frame (30) is installed into shipping pad handle central film (see (31) in FIG. 12). The tab valve main frame (21) is installed in the shipping pad handle top film (see (30) in FIG. 12).

[0069]FIG. 17 provides a perspective view of an inflated two zone (27, 28) shipping pad with its tab valve assembly. Shown are tab valve work frame (20), tab valve main frame (21), zone one air pocket (25) created by pocket notch (23), zone two air pocket (22), created by pocket notch (24) and handle cut out (26) which separates the two zones.

[0070]FIG. 18 provides a perspective view of an alternate embodiment of the invention comprising a four zone shipping pad layout formed with the use of two tab valve assemblies, with each said assembly controlling the flow of air into and out of two of the four pad zones. Shipping pad zone one (50) retains air delivered to one-fourth of the pad area, which air is supplied by manipulating the tab portion of the valve main frame (41) in the first of the two tab valve assemblies. Shipping pad zone two (51) retains air delivered to another one-fourth of the pad area. The air is directed therein by manipulating the tab portion of valve work frame (40) which, in conjunction with main frame (41), forms the first tab valve assembly. A zone one and two air pocket (47) is created by pocket notch (45). The central zone film separates the air and directs air into zones one and two, respectively, depending on the arrangement of the components of the first tab valve assembly.

[0071] Continuing with the description of FIG. 18, shipping pad zone three (48) retains air delivered to another one-fourth of the pad area, wherein the air is supplied by manipulating the tab portion of valve main frame (43) which forms a component of the second tab valve assembly (which also includes tab valve main frame (42) as described below). Shipping pad zone four (49) retains air delivered to the remaining one-fourth of the pad area. The air is supplied by manipulating the tab portion valve main frame (42). The central zone film (see (55) in FIGS. 19, 20) separates the air and directs it to zones three and four depending upon the arrangement of the components of the second tab valve assembly. Tab valve work frame (40) is installed into shipping pad handle central zone film (see (55) in FIG. 20). Tab valve main frame (41) is installed in the shipping pad handle top film (see (30) in FIG. 20). Together, frames (40, 41) form the first of two tab valve assemblies used in forming the four-zone pad according to the invention. Tab valve work frame (42) is installed into the shipping pad handle central zone film (see (55) in FIG. 20). Tab valve main frame (43) is installed in the shipping pad handle top film (see (30) in FIG. 19). Frames (42, 43) form the second tab valve assembly. Handle cut out (52) separates the zones.

[0072] In FIG. 19 lower pad film (29) determines the lower pad dimension from side to side and top to bottom. Upper pad film (30) determines the upper pad dimension from side to side and top to bottom. The central zone film (55) determines the four zone layout. Its film size matches the full pad dimension from side to side and top to bottom in at least the handle portion of the four-zone pad. As shown, it creates air chambers that separate and supply air to each of the four zones.

[0073]FIG. 20 is a view similar to that of FIG. 19, but shows the placement of the tab valve assemblies in the film layers. Lower pad film (29) determines the lower pad dimension from side to side and top to bottom. Upper pad film (30) determines the upper pad dimension from side to side and top to bottom. The central zone film creates the four zone layout. The film size matches the full pad dimension from side to side and top to bottom in the handle portion. Film (55) creates air chambers as shown that separate and supply air to each of the four zones.

[0074] The tab valve work frame (40) of the first tab valve assembly is installed into central zone film (55) in the area of the pad handle. The corresponding tab valve main frame (41) of this first assembly is installed in the top film (30) in the pad handle area. Tab valve work frame (42) of the second tab valve assembly is installed into central zone film (55) in the handle area. The corresponding tab valve main frame (43) of the second assembly is installed in the top film (30) in the pad handle area. Handle cut out (52) (see, e.g., FIG. 18) separates the inflation zones.

[0075]FIG. 21 provides a top plan view of a four zone shipping pad layout with its tab valve assembly. Shipping pad zone one (50) retains air delivered to one-fourth of the pad area, wherein the air is supplied by manipulating the tab portion of valve main frame (41). Shipping pad zone two (51) retains air delivered to another one-fourth of the pad area, wherein the air is supplied by manipulating the tab portion of valve work frame (40). Together, frame portions (40, 41) comprise the first tab valve assembly. The zone one and two air pocket (47) is created by pocket notch (45). The central zone film separates the air and directs it to zones one and two within the pad.

[0076] Shipping pad zone three (48) retains air delivered to another one-fourth of the pad area, wherein the air is supplied by manipulating the tab portion of valve main frame (43). Shipping pad zone four (49) retains air delivered to the remaining one-fourth of the pad area. The air is supplied by manipulating the tab portion of valve work frame (42). Frames (42, 43) together form the second tab valve assembly. The zone three and four air pocket is created by pocket notch (45). The central zone film separates the air and directs it to the respective zones.

[0077] Tab valve work frame (40) is installed into shipping pad handle central zone film (see (55) in FIG. 20). Tab valve main frame (41) is installed in the shipping pad handle top film (see (30) in FIG. 20). Tab valve work frame (42) is installed into the shipping pad handle central zone film (see (55) in FIG. 20). Tab valve main frame (43) is installed in the shipping pad handle top film (see (30) in FIG. 20). Handle cut out (52) (see, e.g., FIGS. 18, 21) separates the inflation zones.

[0078]FIG. 22 is a sectional view through a four zone shipping pad handle with its attendant tab valve assemblies, with both valve assemblies shown in the open position. Shipping pad zone one (50) retains air delivered to one-fourth of the pad area, which air is supplied by manipulating the tab portion of valve main frame (41) of the first tab valve assembly. Shipping pad zone two (57) retains air delivered to another one-fourth of the pad area, wherein the air is supplied by manipulating the tab portion of valve work frame (40) of the first tab valve assembly. Frames (40, 41) together form the first tab valve assembly. The zone one and two air pocket (47) is created by pocket notch (45). The central zone film separates the air and directs it to zones one and two.

[0079] Shipping pad zone three (48) retains air delivered to another one-fourth of the pad area, which air is supplied by manipulating the tab portion of valve main frame (43) of the second tab valve assembly. Shipping pad zone four (49) retains air delivered to the remaining one-fourth of the pad area, wherein the air is supplied by manipulating tab valve work frame (42) of the second tab valve assembly. Frames (42, 43) together form the second tab valve assembly. The zone three and four air pocket (46) is created by pocket notch (45). The central zone film separates the air and directs it to zones three and four. Tab valve work frame (40) is installed into the shipping pad handle central zone film (see (55) in FIG. 20). Tab valve main frame (41) is installed in the shipping pad handle top film (see (30) in FIG. 20). Tab valve work frame (42) is installed into the shipping pad handle central zone film (see (55) in FIG. 20). The tab valve main frame (43) is installed in the shipping pad handle top film (see (30) in FIG. 20).

[0080]FIG. 23 is a sectional view through a four zone shipping pad handle showing the two tab valve assemblies in the closed position. As described above, shipping pad zone one (50) retains air delivered to one-fourth of the pad area, wherein the air is supplied by manipulating the tab portion of valve main frame (41). Shipping pad zone two (51) retains air delivered to another one-fourth of the pad area, which air is supplied by manipulating the tab portion of valve work frame (40). The zone one and two air pocket (47) is created by pocket notch (45). The central zone film separates the air and directs it to zones one and two.

[0081] Continuing with the description of FIG. 23, shipping pad zone three (48) retains air delivered to another one-fourth of the pad area, wherein the air is supplied by manipulating the tab portion of valve main frame (43). Shipping pad zone four (49) retains air delivered to the remaining one-fourth of the pad area. The air is supplied by manipulating the tab portion of valve work frame (42). The zone three and four air pocket (46) is created by pocket notch (45). The central zone film separates the air and directs it to zones three and four. The tab valve work frame (40) is installed into the shipping pad handle central zone film (see (55) in FIG. 20). The tab valve main frame (41) is installed in the shipping pad handle top film (see (30) in FIG. 20). The tab valve work frame (42) is installed into the shipping pad handle central zone film (see (55) in FIG. 20). The tab valve main frame (43) is installed in the shipping pad handle top film (see (30) in FIG. 20).

[0082]FIG. 24 provides a perspective view of an inflated four zone shipping pad with its respective two tab valve assemblies. The features illustrated are common with those of FIGS. 18 and 21 and are identified with the same identification numbers as used therein.

[0083] As shown in FIG. 25, the shipping pads of the invention can be located in a variety of positions within an outer shipping container to completely support interior items (61) in a shipping carton (60). The pads can be placed, for example, in each corner (63) and optionally around the sides of the interior item (61). Moreover, the pads can additionally be folded to protect the bottom (62) and top (64) of the interior items.

[0084]FIG. 26 illustrates a smaller (than the one shown in FIG. 25) shipping carton (60) containing a smaller package (61), which package (61) can be completely supported with just a corner (63) configuration that wraps from the bottom to the top of the interior item.

[0085]FIG. 27 illustrates that the shipping pads produced according to the invention can be folded and then inflated within a package to fill wider spaces (i.e., wider than the thickness of a single pad) with the use of only one. Illustrated is a pad comprising zone one (28) and zone two (27), tab valve working frame (20) that controls entry of air into zone two, separated by a central film and air pocket (22), and tab valve frame (21) that controls entry of air into the first zone, separated by a central film and air pocket (25).

[0086] As shown in the accompanying drawing figures, the present system includes everything needed to provide a packing system that can be inflated, deflated, and reused. The shipping pad of the invention is thus designed to hold an item or inner package secure in a exterior shipping carton (see FIGS. 25, 26). The system may be configured, in a first embodiment in a two zone format (see, e.g., (14, 15) in FIG. 14) wherein the two zones are created by bonding two film sheets together (see (29, 30) in FIG. 12) wherein a central film ((31) in FIG. 12) is interposed between at least a portion of films 29, 30 to provide an air chamber for each zone, and, in a second embodiment, with a four zone design (see FIG. 21) with four areas of inflation in FIG. 21) created by heat welding three film sheets, ((29),(30),(55) in FIG. 19) together, with the central film sheet (see (55) in FIG. 19) creating air chambers for each zone.

[0087] Additional security is provided by the use of a geometric, heat welded design that provides a balanced height ratio in each zone. If a zone is punctured this geometric design will allow the other zone or zones to continue to support the interior package. The preferred geometric design involves the use of cone-shaped inflatable chambers to form the pad zones. The wide backs of the cone design and the sharp points of each cone are positioned to provide a height balance in each zone (see FIGS. 14, 21).

[0088] Pad zones each comprise multiple interconnected air chambers to provide each pad with the maximum ability to absorb impact by distributing air to chambers not compressed by the impact. The pads of the invention may be formed of any number and type of film substrates that can be welded together by, e.g., applying heat, or by an electrical or chemical bonding process. Materials useful in the formation of the films used in forming the invention are well known among those of ordinary skill in this field and the particular choice of material is not critical to the invention. Moreover, varying the film thickness provides for varying levels of pad strength and security, and can be dictated as the product to be shipped or the budget require. Virtually any film that can hold air and can be securely welded together can be used to create a zoned shipping pad in accordance with the invention.

[0089] The air in each zone of a pad is retained by a tab valve assembly, (see FIGS. 15, 16 and 22, 23). The tab valve assembly provides an air entrance (see (6) in FIG. 9), a three-point locking system (see (13),(14),(15), FIG. 10) (see below) and a tab release feature (see (2) in FIGS. 1, 2) for the air contained in the pad. The valve design is a simple structure with no moving parts, which is easy to manufacture and assemble and which provides an acceptable substitute for the valve types used in current low cost packing materials. The tab valve frame supplies air flow through an air portal (see (6) in FIG. 1). When the position illustrated in FIG. 15 and FIG. 22, the main tab valve frame allows air through its portal (see (6) in FIG. 9), and into air chamber (see (25) in FIG. 15). This allows air to move to zone one of a two zone pad, and thereafter through working tab valve frame (see (20) in FIG. 15) to air pocket (see (27) in FIG. 9) to inflate zone two of a two zone pad. Once the pad is inflated the main valve body frame (see (21 in FIG. 15) and the working valve frame (see (20 in FIG. 15) are snapped together (see (20, 21), in FIG. 16), thus locking the valve assembly and closing the shipping pad to air flow.

[0090] As noted above, the tab valve frames contain three locking points (see FIG. 9 (7), (4), (9)). The most prominent snap lock feature is the valve body stem lock (see (9) in FIGS. 8 and 9). When a main valve frame is positioned over a working valve frame the main frame stem snap lock is directly above the air portal in the working valve frame (see (8), (6) in FIG. 9). When the main and working valve frames are snapped together the stem fills the portal in the working valve frame (see (13) in FIG. 10). The fit is flush to the bottom of the working valve seat body (see (10) in FIG. 1O), to permit the air pressure against the bottom of the valve to be distributed over the complete valve seat surface, thus enhancing the integrity of this snap fit.

[0091] The second snap lock is located inside the valve seat body, protecting it from any external pressure against the valve seat body (see (4) in FIG. 9). This arrangement allows the working valve body to snap into the air portal of the main valve frame (see (14) in FIG. 10), thus sealing off any air pressure through the main valve frame when the valve assembly is closed (see FIG. 16).

[0092] The third locking point is created by seating the valve seat body (see (10) in FIGS. 8, 9) into the working valve frame. The valve seat locking ridge (see (7) in FIG. 2), that wraps around the inside of the working valve frame, snap locks into the valve seat body groove (11 in FIG. 8) that completely wraps the outside of the exterior valve seat of the main valve frame FIG. 8.

[0093] An additional seal is created by welding each valve frame to its corresponding film layer (see FIG. 15) at a point on the bottom of the frame body (see (3) in FIG. 8).

[0094] A valve assembly is opened by pressing down on the working frame tab (see e.g., (2) in FIG. 2 and (8) in FIG. 4), and lifting up on the main frame valve frame tab (see (2) in FIGS. 1, 4). Pressing down on the working valve frame (see (8) in FIG. 4), spreads the locking ridge (see (7) in FIG. 2) and body groove (see (11) in FIG. 8) open a little, and lifting up on the main frame valve tab (see (2) in FIG. 1) provides a peeling action, allowing the locking ridge (see (7) in FIG. 2) to release the body groove (see (11) in FIG. 8) while allowing the snap stem (see (9) in FIG. 8) to be removed from the air portal of the working valve frame (see (6) in FIG. 9) and releasing the final snap seat (see (14) in FIG. 10). When the valve assembly is thus opened air moves out of the pad through the air portals of each valve frame and the pad is deflated.

[0095] Valve frame body FIG. 1, FIG. 2, can be produced by casting any plastic material that can maintain a relatively rigid frame profile, yet remain sufficiently flexible when the frames are snapped open and closed. The plastic material must additionally be able to keep its shape and valve integrity throughout the useful life of the tab valve and shipping pad.

[0096] The four-zone shipping pad (FIG. 21) of the invention has all the features of the two-zone system, including an additional, i.e., second tab valve assembly, with the same valve features of air entry, locking and release in the same manner described above for the two zone pad. Additional security is offered by the four-zone pad in that there is a central film layer (see (55) in FIG. 19), in each four-zone pad that divides the inflated section into four complete zones (see (48), (49), (50), (51) in FIG. 21, and (48), (49), (50), (51) in FIG. 22). The interior film provides an additional area for absorbing impact. That is, when one of the exterior film areas (see (29), (30) in FIG. 19 and (29), (30) in FIG. 22), is subjected to an impact, the resulting force can be absorbed by this soft flexible middle film layer (shown as (55) in FIGS. 19, 22).

[0097] This multi-zone feature adds a level of puncture resistance to the pad surface. That is, the use of four zones allows the pad to maintain a greater level of integrity if a zone is punctured. The four-zone system additionally adds a level of valve security, with a first tab valve assembly (see (40), (41) in FIG. 21) controlling zones one and two, and a second tab valve assembly (see (42), (43) in FIG. 21) controlling zones three and four. Valve assembly one (see (40), (41), in FIG. 21 22) includes a main valve frame, (see (41 in FIG. 22). The air moves through air portal (see (6) in FIG. 1), of the main valve frame (see (41) in FIG. 22), and into zone one, then through another air portal (see (6) in FIG. 2) of the working valve (see (40) in FIG. 22) and through to zone two. The divider for these two zones is created by the handle cutout (see (51) in FIG. 21) and the central film layer illustrated, e.g., as (55) in FIG. 19.

[0098] The second tab valve assembly (see (42),(43), in FIGS. 21, 22) also includes a main valve frame (see (43) in FIG. 22 ), The air moves through air portal (see (6) in FIG. 1), of the main valve (see (43) in FIG. 22), and into zone three, then through air portal (6) in FIG. 2), of the working valve (see (42) in FIG. 22 ) and through to zone four. The divider for these two zones is created by the handle cutout (see (52) in FIG. 21), and the central film layer (see (55) in FIG. 19). In the four-zone embodiment the two valve assemblies are closed in the same manner as the two-zone system described above. Each two zone section is controlled by a separate tab valve assembly. Both valve assemblies will need to be open to deflate the pad completely.

[0099] As noted above, shipping pads in accordance with the invention can be placed on each corner (see, e.g., (63) in FIG. 25) of the interior package and then inflated, thus preventing the interior package from moving back and forth within the container. Shipping pads produced according to the invention can also be placed on the bottom of the exterior carton. The interior package can be lowered onto two, or four deflated shipping pads which may thereafter be inflated so as to surround each side of the inner container. Alternately, deflated shipping pads may be inserted down each side of the interior package and then inflated. (see (64) in FIG. 25) The pads may be folded to further prevent the interior package from moving up and down during shipping. For a smaller or lighter interior package, pads surrounding each corner of the package, (see (60) in FIG. 26) can provide support for both the up and down movement and the side to side movement, with the use of only four properly sized shipping pads.

[0100] It is to be understood that the present invention is not limited in scope by the exemplified embodiments which are intended as illustrations of single aspects of the invention, and embodiments and methods which are functionally equivalent are within the scope of the invention. Indeed, various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description. 

What is claimed is:
 1. An impact-resistant packing system for protecting articles during shipping from shock and damage, said system including a reusable, inflatable shipping pad, said pad comprising first and second outer film layers and a third, central film layer interposed between said first and said second film layers, said first and said second film layers being secured together along an outer perimeter thereof to define an inner volume within said pad and said third, central film layer being secured at opposed ends to, respectively said first and said second film layers within said inner volume in a location selected to form at least two separate zones within said inner pad volume, said pad further comprising at least one tab valve assembly configured and adapted to permit repeated independent inflation and deflation of each said zone.
 2. The system of claim 1, wherein said pad comprises a single tab valve assembly configured and adapted to form two separately repeatedly inflatable and deflatable zones within said pad inner volume.
 3. The system of claim 1, wherein each said tab assembly comprises a first and a second tab valve frame, wherein said first frame is mounted in said first or said second outer film layer, and said second frame is mounted in said third, central film layer adjacent said first frame and positioned to permit a snap-locking engagement therewith.
 4. The system of claim 3, wherein each said tab valve frame comprises a frame portion provided with a tab portion extending therefrom, and wherein said frame portion further comprises a valve seat snap lock, a valve seat opening, an air portal, a valve seat locking ridge, and a valve seat body groove.
 5. The system of claim 4, wherein said valve frame tab portions are adapted to permit closing and opening of said valve assembly by respectively snapping together and pulling apart said valve frames by use of said tab portions.
 6. The system of claim 4, wherein said valve seat body groove is configured and adapted for capturing a valve seat locking ridge of a corresponding valve frame of said tab valve assembly to assist in securing said first and said second tab valve frames together.
 7. The system of claim 4, wherein said valve seat snap lock is configured and adapted to substantially completely seal an air portal of a corresponding valve frame of said tab valve assembly.
 8. The system of claim 1, wherein each said zone is comprised of a plurality of inflatable chambers configured and adapted to redistribute an inflation gas contained therein from one or more chambers compressed by an external impact to at least one contiguous chamber which is not impacted.
 9. The system of claim 8, wherein said chambers are each substantially conical in shape.
 10. The system of claim 9, wherein a height ratio of the conical chambers is balanced by alternating between restricted entry cones and open entry cones.
 11. The system of claim 1, wherein said pad further comprises a cut-out handle area adjacent one end of said pad, said handle area adapted for separating the inflatable zones and for creating an alternate relief area for inflation gas compressed due to an impact upon a remaining main fill area of the pad.
 12. The system of claim 1, wherein said first, said second and said third film layers are each formed from a plastic film-forming material.
 13. The system of claim 1, wherein said film layers are secured together by heat sealing, sonic welding or other electrical bonding process, by an adhesive, or by a chemical bonding process.
 14. An impact resistant packing system for protecting articles during shipping from shock and damage, said system including a reusable, inflatable two-zone shipping pad, said pad comprising first and second outer film layers secured together along an outer perimeter thereof to form an inner pad volume, and a third, central film layer interposed between said first and said second film layers within said pad volume and secured, at opposed ends, respectively to said first and said second film layers in a location selected to form two separate zones within said volume, said first, second and third film layers being comprised of a plastic film forming material, said pad further comprising a tab valve assembly comprising a first main valve frame and a second working valve frame, respectively, said valve frames configured and adapted to be snapped together and pulled apart to permit repeated independent inflation and deflation of each said zone.
 15. The system of claim 1, wherein said pad comprises two separate tab valve assemblies configured and adapted to form a total of four separately repeatedly inflatable and deflatable zones within said pad inner volume.
 16. The system of claim 15, wherein each said tab assembly comprises a first and a second tab valve frame, wherein said first frame is mounted in said first or said second outer film layer, and said second frame is mounted in said third, central film layer adjacent said first frame and positioned to permit a snap-locking engagement therewith.
 17. The system of claim 16, wherein each said tab valve frame comprises a frame portion provided with a tab portion extending therefrom, and wherein said frame portion further comprises a valve seat snap lock, a valve seat opening, an air portal, a valve seat locking ridge, and a valve seat body groove.
 18. The system of claim 17, wherein said valve frame tab portions are adapted to permit closing and opening of said valve assembly by respectively snapping together and pulling apart said valve frames by use of said tab portions.
 19. The system of claim 17, wherein said valve seat body groove is configured and adapted for capturing a valve seat locking ridge of a corresponding valve frame of said tab valve assembly to assist in securing said first and said second tab valve frames together.
 20. The system of claim 17, wherein said valve seat snap lock is configured and adapted to substantially completely seal an air portal of a corresponding valve frame of said tab valve assembly.
 21. The system of claim 15, wherein each said zone is comprised of a plurality of inflatable chambers configured and adapted to redistribute an inflation gas contained therein from one or more chambers compressed by an external impact to at least one contiguous chamber which is not impacted.
 22. The system of claim 21, wherein said chambers are each substantially conical in shape.
 23. The system of claim 22, wherein a height ratio of the conical chambers is balanced by alternating between restricted entry cones and open entry cones.
 24. The system of claim 15, wherein said pad further comprises a cut-out handle area adjacent one end of said pad, said handle area adapted for separating the inflatable zones and for creating an alternate relief area for inflation gas compressed due to an impact upon a remaining main fill area of the pad.
 25. The system of claim 15, wherein said first, said second and said third film layers are each formed from a plastic film-forming material.
 26. The system of claim 15, wherein said film layers are secured together by heat sealing, sonic welding or other electrical bonding process, by an adhesive, or by a chemical bonding process.
 27. An impact resistant packing system for protecting articles during shipping from shock and damage, said system including a reusable, inflatable four-zone shipping pad, said pad comprising first and second outer film layers secured together along an outer perimeter thereof to form an inner pad volume, and a third, central film layer interposed between said first and said second film layers within said pad volume and secured, at opposed ends, respectively to said first and said second film layers in a location selected to form four separate inflatable zones within said volume, said first, second and third film layers being comprised of a plastic film-forming material, said pad further comprising two tab valve assemblies, wherein a first said assembly is associated with a first and a second inflatable zone of said pad and a second said assembly is associated with a third and fourth inflatable zone of said pad, each said tab valve assembly comprising a first main valve frame and a second working valve frame, respectively, said valve frames configured and adapted to be snapped together and pulled apart to permit repeated independent inflation and deflation of each said zone associated therewith. 